Plastic forming apparatus and method



Aug. 17, 1948.

Filed July 5, 1944 G. A. LYON 2,447,415

PLASTIC FORMING APPARATUS AND METHOD 4 Sheets-Sheet 1 650205 fl; after Ava/v.

Aug. 17, 1948. 7 cs. A. LYON 2,447,415

PLASTIC FORMING APPARATUS AND METHOD Filed July 5,1944 7 -4v Sheets-Sheet 2' YRVEZ 'ZZQF" 62-0205 (91.55127- [JO/V.

mg. 17, 1948. G. A. LYON 2,447,415

' PLASTIC FORMING APPARATUS AND METHOD v Filed July 5, 1944 4 Sheets-Sheet 3 1 I9 *35 i g4 Z0 29 g 36 i 34 i 5 i i i 34 i L J L "l L J 17, 1948. G. A. LYON 2,447,415

PLASTIC FORMING APPARATUS METHOD 4 Sheets-Shet 4 Filed July 5, 1944 30 za 3? a v ZnIEn 2:71

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Patented Aug. 17, 1943 UNITED STATES PATENT OFFICE PLASTIC FORMING APPARATUS AND METHOD George Albert Lyon, Allenhurst, N. J.

Application July 5, 1944, Serial No. 543,525

17 Claims. 1

This invention relates to an apparatus and method for forming plastic material into sheets, and more particularly to a method and apparatus for pressing plastic material into sheets or blanks.

In forming plastic material into sheets, it is important to avoid the formation of air bubbles in the sheets, which bubbles result from the entrapment of air in the plastic material. Furthermore, it is desirable to form the sheets with smooth, polished surfaces so that the finished product may have a pleasing appearance and be easily cleaned without requiring a separate polishing step.

The invention contemplates the pressing of plastic into sheets in a rarefied atmosphere and between highly polished surfaces, so that sheets produced by this apparatus and method will be substantially free of air'bubbles and have smooth, polished surfaces.

It is an object of this invention to provide an apparatus for forming plastic material into sheets in a rarefied atmosphere.

Another object of this invention is the provision of apparatus for pressing plastic material into sheets which includes means for removing freshly formed sheets from the face of the pressing element without marring the sheets.

A further object of this invention is the provision of integrated apparatus for heating plastic material, pressing it into substantially flawless and polished sheets, and carrying the material through the heating and pressing means without necessitating manual handling of the material.

Still another object of this invention is the provision, in apparatus for pressing plastic material into sheets, of a conveyor which provides one of a pair of smooth, highly polished pressing surfaces to impart a smooth, polished surface to the sheets pressed from the material.

It is also an object of this invention to provide a method of pressing plastic materials into sheets in which the pressing operation is carried out in a rarefied atmosphere to avoid defects in the pressed sheets caused by entrapped air.

Another object of this invention is to provide a method of forming sheets from plastic material which includes heating the material, pressing the material in a rarefied atmosphere and between highly polished surfaces, and removing the pressed sheets from.- the pressing element" by directing a fluid blast between the adhering faces of the pressing element and the sheets.

A further object of the invention is to provide a method of pressing plastic material into sheets Other and further objects and advantages of the invention will be apparent to those skilled in the art from the following description and the appended claims.

In the drawings: I

Figure 1 is a front elevational view of the press forming part of the apparatus, with a mass of plastic material in position to be pressed;

Figure 2 is a brokenside elevational view of the apparatus of this invention;

Figure 3 is a broken plan view of the apparatus;

Figure 4 is a sectional View of the pressing parts of the apparatus with one element enclosing the plastic material;

Figure 5 is aview similar to Figure 4 but with the parts in their pressing position;

Figure .6 is a view of a portion of Figure 5 with the movable pressing element in a partially retracted position; 1

Figure '7 is a plan view of a ring of plastic material to be pressed into sheet form;

Figure 8 is a cross-sectional View taken on the line VIII-VIII of Figure '7;

Figure 9 is a plan view of a plastic sheet produced from the plastic ring of Figure '7; and

Figure 10 is a cross-sectional view of the sheet. shown in Figure 9, taken on the line X--X of that For convenience, the invention is described as applied to the production of blanks for plastic trim rings for use on automobile wheels, but it will be readily appreciated that the invention is applicable generally to the production of sheets from plastic material.

A suitable double-acting press II is provided.

connects with a pipe [9 secured within the pis-- ton and extending to near the bottom thereof, which acts asan inlet and a discharge conduit for thecooling medium. The pressing face I6 of the piston 13 has an aperture 20 in the center thereof opening into a tube 2| which extends 3 through the piston to communicate with bores 22 formed in the upper portion I of the piston, so that a passage for fluid such as air is provided through the piston I3.

The press II also has a plurality of secondary rams 23 which actuate a generally cylindrical member 24 in which the piston I3 may reciprocate. The cylindrical member 24.has coaxial upper and lower portions 25 andr26, respectively, the upper portion being of greater diameter than the lower portion. closed at the top by a cover member 21 having an aperture through which the ram IZ passes'. The

The upper portion 25 is inner diameter of the upper portion 25 corretion I5, and the inner diameter of the lower cylindrical portion 26 correspondstotthe' dian'ie v ter of the lower piston portion I4. It willbe member comprises a chamber closed by the cylindrical wall of the portion 25; the cover member 21 'andthe upper piston portion I5, and that the lower cylindrical portion-26 forms a cylindrical chamber open at one end and'closed at the'other endbythelower or pressing portion llofthewiston ta. The-length or'the lower piston portion I4 is such that when the lower portion has reached its extremepressing position theupper piston portion-I5- is held clear of the cylindrical wall of the lower cylindrical portion 26, and when the-piston is in its extreme retracted position the pressing face I6 is still within the lower cylindrical portion 26;

The'press H has a bed -28 whichis heated by a heating medium such as steam introduced into-'the bed-through'a conduit 29. The plastic material to bepressed intoa sheet is brought into position on the heated bed' 28-" below the pressing face I'S df the piston I3 by means of an endless conveyor: 30, }which'may he supported at intervals along-its length byrollers Sito prevent unduesagging thereof: The conveyor-30 passes through a furnace or other heating'means represented diagrammatically at- 3-2, disposed between the receiving end-oi the conveyor and thepress H, and'also passes through the press II, the upper leg of theconveyor passing over ing its travel therethrough is brought to proper forming: temperature; The. plastic material may beofany clesired-type-,:and, by wayof example only, cellulose acetate, cellulose acetate butyrate, andethyl cellulose are mentioned, but it will beztunderstood that the-inventionis applicable tovarious other typeset plastic material. The material may be'in'any desiredform, such as powder, granularpqor. solid: form, such as an extruded plasticrod; In; general; a plastic. rod is preferable since it maybe. handled moreeasilyandspeedily thanthe granular v particles, and minimizes the possibility of aircentrapment in the sheet.

From the furnace 32 the plastic:1.'ing:33 is car-J ried by-the conveyor into-the press I! and centered'beneath the pressing face i610 As=-will be,

clear,:the ringz33 rests; on: the conveyorBilwhich. in turn-rests on; the: heatedbed 28; Thepi'ston I3. is, heated to' a proper "temperature: by steam or-other heating mediumvintloduced through the conduit I1; and the rams l2 and 23'jare, operated seen that the upper portion 25 of the cylindrical 4 to move the cylindrical member 24 and the hollow piston I3 toward the bed 28. As will be obvious, the lower edge of the lower piston portion 26 contacts the conveyor 30 and clamps it tightly against the bed 28, and thus the conveyor 38 provides a solid, level and highly polished pressing surface for the ring 33. The lower edge of the cylindrical portion 26 carries a ring 34 of resilient material which provides a substantially air-tight seal between the conveyor 39 and the lower cylindrical portion 26. Suitable sealing rings 35 are provided in the peripheries of the lower piston portion; I liand theupper piston portion I5 to provide substantially air-tight engagement between the piston .portionsand the corresponding portions of the cylindrical member 24. It will thus be seen thatsvhentherlower cylindrical portion 25 is held against the conveyor 39, two air-tight chambers areprovided, one in the upper cylindrical portion as already described, and the other in the lower cylindrical portion 26 closed by the conveyor 38,

the wall of the lower portion 26, and the pressing face it 'of the piston I3; 5 Communication between the chambersis afforded by-thepassageway 2| a suction effect .due .to:the.-:diflerence in'the size of the upperiand lowenchambers as. the piston lfiimovesnt'o its.:pressing:position. Since the chambers' are air-tight, the; air expands to fill the upper chamber as its volume increaseswhile' that of the lowerichambendecreases upon movement of the piston I3. to pressing position. This expansion of the ain't-he. upper-chamber produces asuctiorr effect in thellower chamber which removes'rsubstantially. of the: air in the lower chamber astheupiston'presses the ring 33. The

pressing of the-:ring 33 into the. sheet 33a is therefore accomplished in: a rarefied atmosphere, which substantially prevents theformation .of

' air bubbles in the: plastic. material", either. within the: body oiithe-materlal or at the. surface, and thus results ina sheet or blank-which is perfect both. in'structurezand: appearance; The highly polishedzsurfaces ofthe pressing face it and the conveyor: idim-partta smooth; polished surface to the sheet or blank 33cc.

During thedwelloflthe. pressing face I6 on the plasticzmaterial, thepi-ston I3 is: cooled, as the introduction-of water through the conduit I8 and the pipe lainto the-interiorthereof, in-

orderto reduce to-a. minimum the possibility of the: sheet 33ai'sticking' to the face IB when the piston: I aisretractedi The-water or other coolantis pumpedt-outthroughzthe pipe: I9 and conduit I8 as the piston I3 moves to itsiretr-acted position.

It will be obvious that the heating and cooling means for the piston I3 and theheating means for the bed- 28 may-beof anydesired type, and need nottakelthe particular form shown and described herein. It will also be obvious that the air passagabetween. thechambersneed not be positionedcentrally of the-piston, and furthermorethat it needn'ot pass throughthe piston.

Toinsure'against the possibility of asheet 33a adhering. to ithelpressing: face iii of tho piston 5. despite the cooling of the piston, means. are provided-to remove any sheet which may adhere to the face 16 without marring the sheet. As shown, the means comprises a pipe or the like 36 secured about the lower cylindrical portion 26 near the bottom edge thereof and communicating with the interior of the portion 26 by means of passages 31 provided through the wall of the portion 26 at intervals therearound. A conduit 38 is connected to the pipe 36, and through this conduit fluid under pressure, such as compressed air, may be introduced into the lower portion 26 as a plurality of streams or blasts through the passages 31 and pipe 36. The passages 31extend through the wall of the lower cylindrical portion 26 at an angle to direct the stream of compressed air or the like upwardly, and the compressed air or other fluid is introduced at the moment when thepiston l3 in its retracting movement has reached a position slightly spaced from the con-v veyor 36, so that the streams of compressed air willimpinge against the pressing face IE5 at the edge of the sheet 33a. It will be clear that since the bed 28 is heated and the pressing face 16 is cooled during the dwell of the race I6 on the plastic material in the pressing operation, the sheet 33a will tend to adhere to the conveyor 36 rather. than to the face, l6; but in the event the sheet 33a does adhere to the face l6, it is removed by the blast of compressed air passing about the circumference of the sheet between the face I6 and the sheet 33a. It will be appreciated that the compressed air or the like has a double removing effect on the sheet 33a, since it tends to cool the sheet and thereby overcome or loosen its adhesion to the face l6, and at the same time the force of the blast peels the sheet from the face IS. The use of compressed air or other fluid has another advantage, in that the sheet may be removed without marring the surface thereof, which would not be the case were a knifeor scraper used for this purpose.

As the piston I3 is retracted, the air in the upper chamber is forced into the lower chamber, and after the piston l3 has reached its fully retracted position in the cylindrical member 24 the cylindrical member 24. is also retracted with further retractin movement of the piston I3 to bring the pressing parts into substantially the position shown in Figure 1. It will be obvious; that as the piston is retracted in the cylindrical membet, the air will return to the lower closed chamher under normal pressure, and that therefore there will be no difficulty in breaking the seal bet weenthe lower cylindrical portion 26 and the conveyor 30.

As the piston I3 and cylindrical member 24 are brought to fully retracted position, the conveyor 30 is operated to carry the sheet 33a out of the press and bring another ring 33 into position for pressing. It will be obvious that the conveyor 30 is operated in synchronism with the operations of the press I l, and this synchronization may be obtained in any suitable manner. The air blast, of course, is also synchronized with the operation of the press, and this synchronization similarly may be obtained in any suitable manner.

' As the sheets or blanks 33a leave the press, they may be carried to a forming die or the like to be given a desired cross-sectional contour, or to some other device or machine for another ,operation., It may therefore be desirable to maintain the sheet 33a at a suitable temperaturaand for this purpose a suitable heating means is represented diagrammatically at 33 .in Figure 2;

6: After leaving the conveyor 30, the sheet 33a may, be suitably trimmed at its: inner and outer -peripheries to give the sheet aform similar to that illustrated in Figures 9 and 10, or the trimming. may be postponed until after a further operation has been performed on the sheet 33a.

It will, of course, be understood that various details of construction may be varied through a wide range without departing from the principles of this invention and it is, therefore, not the purpose to limit the patent granted hereon otherwise than necessitated by the scope of the ap-' pended claims.

Iclaim as my invention:

1. In an apparatus for forming plastic mate-- rial into sheets, in combination, a double-acting press, a conveyor carrying the plastic material into position in the press, and means in said press for holding a portion of said conveyor against the press bed and sealingly enclosing plastic material thereon, said means including a portion movable relative to the rest of said means for simultaneously pressing said material and means substantially exhausting air from said first mene tioned means.

2. Apparatus for forming. sheets from plastic material comprising a press, a first cylinder in said press open at both ends and movable to seal the bottom edge thereof against the press bed, a second cylinder of larger diameter than said first cylinder disposed above and secured to said first cylinder, a pressing plunger reciprocable in said cylinders having a lower piston portion in said first cylinder and an upper piston portion in said second cylinder, conduitmeans to permit passage of air from one cylinder to the other, and means to direct a fluid stream upwardly against the plunger face.

3. An apparatus for forming plastic material into sheets comprising a double-acting press with a heated bed, an endless conveyor passing through said press to carry plastic material to be sheeted, chamber means in said press having two portions of difierent, cross-sectional area, said means being movable to press the smaller portion against a portion of said conveyor to hold said conveyor portion tightly against said bed, a piston with portions closely fitting and movable in said portions of said chamber means and form ing chambers therewith of different areas, a passageway through said piston connecting said chambers, said piston portion in the smaller chamber pressing upon plastic material carried by the conveyor to form a sheet of said material.

4. An apparatus for forming plastic material into sheets comprising a double-acting press with a heated bed, a plastic material conveyor passing over said bed, chamber means in said press having a lower portion and an upper portion of greater cross-sectional area than said lower portion, said chamber means being movable to clamp said conveyor between the bottom edge of said lower portion and said bed, a, hollow double-faced piston movable in said chamber means, the lower face of said piston constituting a pressing face snugly fitting in the lower portion of said chamber means and forming a lower chamber therewith and with said conveyor and the upper face Of said piston snugly fitting in the upper portion of the chamber means and forming a chamber therewith, a passage through said piston connecting said chambers, heating means for said piston, and cooling means for the'piston.

5. In a double-acting press for plastic material, a heated bed, a piston to press plastic material on 7 mid; beige flange on the=upper orti n-of the pistomsmeans for heating and. means. ion-c001 ing-saidipistoma chamber element: comprising an upper-walled portion snugly receiving: said" flange anda 'lowerwalled'portion forming a cylinder for said piston; said'ichamber. element belng..movab1e to engage the bottom edge oi said lower: portion against said had :and about the plastic materiaLaa, passage through said piston and fiangetopcrmit escape-chair from said lower:

chamber element portiom tosaid upper portionupon: downward =movementof saidpiston and flange in said lower portion and upper portionrespectively, and means tokiirect a fluid stream against-the face'or the piston;-

6. In an apparatus 1 for forming sheets from plastic material oomp'rising a furnace anda conveyor passing through-said'furnaceand carry;- ing plastic material, a'press comprising a bed over which said; conveyor passes,--a cylindrical member open :ataits lower-end and having-an upper portion and-a lower portion of smallerdiameter than;-.:said upper portioma pressing'piston' re ciprocabie in-said-lower portion and havingan upper end of a diameter correspondingto' that of said upper cylindricalportion and reciprocable thereingsaid-upper piston-end and-upper cylinder' portion forming anupper chamber and saidpiston and lower cylindrical portion forming a, lowerchamber; saidcylindrical member being movabieto enclose the-plastic material in said lower. chamben-iand a passageway through said piston and upper piston end communicating with said chamber.

'1. Iman apparatus for'pressing plastic mateinspections of different diameters; piston'means havingportions fittingin said sections, said pis ton: means being reciprocable in said cylindrical member to increase. the eitective volume of the I-argersdiameter sectionwto more than the maximumvoiumcof the-other section and topress plastic-materiaii'in the smaller diameter section, and air. passagermeans connecting said sections.

8; A method of forming plastic material into sheets comprising conveying the material through adurnace-i torheatsaid material, placing the heated matcrial onwa heated press bed, sealing said: material from. outside atmosphere, substantiallvcexhausting air from.-a'bout said material, pressingsaid material between said bed and a heated press element, holding said material under pressure, cooling said heated press element, releasing said pressure; and blowing air against the bottom of said press element and inwardly toward the edge of the pressed plastic sheet and between said edge and thepress element to re move therefrom the sheet formed ofsaid plastic material.

9..In an apparatus of the class described, an intermittently moving endless belt having a highly polished surface carrying spaced masses of plastic material to be formed-into sheets, means defining an-areathrough which said belt passes for conditioning said-plastic material, a substan tially fiat'supporting surface over which said belt passes; after passing through said conditioning area, means movable toward andaway from said belt and adapted forholding a portion of said belt tightly againstsaid surface, and a pressing element movable relative to said holding means and having a highly'pollshed pressing surface for pressing a mass of material-on the held-portion of the belt against the resistanceof said support ing surface and between saidspolished surfaces toimpart a sheet form and smooth suriacesthereto;

10. Apparatus for forming plastic material into sheets comprising, in combination, means for heating said material, means defininga first closedarea of variable capacity within which the material is received and a second closed area of greater cross sectional area than that of said first area and of inversely variable capacity communioating with said first area, said means ins eluding a movable structure operable for contracting said first area to contemporaneously displace air therefrom into said second area to expand in said second area whereby to rarefy the air in both of said-areas.

11". Apparatus for forming plastic material into. sheets, comprising means defining a first Variable closed chamber and a second variable closed chamber of greater cross sectional area than that of-said first chamber and of greater maximum capacity communicating with said first chamber; and mechanism for contemporaneously ex' panding said second chamber and contractingsaid first chamber, said means includinga pressing surface operable in said first chamber to press said materialduring rarefication of the atmosphere.

12. Apparatus for shaping plastic material comprising, in combination, means defining a first variable closed chamber and a communicating second variable closed chamber of greater cross sectionalarea than that of said first chamberand spaced from the first chamberby a movable pressing member forming a separatingwall therebetwecn, and means for moving said pressingmember to shape the material and containporaneousiy extract substantially all of the air from said firstchamber by expanding-said seccud-chamber to a volume greater than the maximum volume of said first chamberwhile'ccntracting said first chamber.

13; Apparatus for forming plastic material into sheets comprising, in combinatiom-a forming station, means for heating said material; means for'feeding said material progressively byprodetermined' individual units to the formingstatlon, means at said station defining-a first closed areaof variable capacity within which the successive units of material are adapted to be sealed and-a second closed area'of greater cross-sectional area than that of said first area and of inversely variable capacity communicating with the first area, said area-defining means including a movable structure operable to contract said first area to contemporaneously force air therefrom into said second area and expand said second area to rareiy the air in both of said areas and press the material, and means for operating-said feeding means in timed sequence with said areadefining and pressing means.

14."In combination in apparatus for pressing plastic material into thin sheet form, means providing a smooth pressing base to receive plastic material to be pressed thereagainst, a tubular structure movable axiallyinto and out of sealed closing relation to said pressing base, a piston structure guided for axial movement within said tubularstructure and operable in sequential relation thereto for pressing the material against said base and having a smooth pressing face op-' posing said base, means for rarefying the atmosphere within said tubular structurebetween said baseand said pressing face during the pressing operation, said tubular structure having a uniform series of pressure fluid ports directed inwardly from the inner wall thereof, and means operable when the piston structure is retracted from said pressing base to force pressure fluid through said ports and between said pressing face of the piston structure and the sheet of pressed plastic material whereby to break any vacuum seal existing between the sheet and said face and strip the sheet therefrom.

15. In combination in apparatus for pressing flat plastic sheets of ring form from ring shaped rods of plastic material, means providing a smooth pressing base for supporting a plastic ring rod to be pressed, a cylindrical tubular structure cooperable with said base to sealingly enclose the area occupied by said ring of material to be pressed, a piston structure slidably guided within said tubular structure and having a pressing face opposed to said base for pressing the rod ring therebetween into a ring shaped sheet, said pressing face having a central opening therein, and means for substantially evacuating the atmosphere between said base and face through said opening substantially coincident with the pressing operation.

16. The method of making ring shaped blanks of thin sheet plastic material, comprising subjecting individual ring shaped rods of the plastic material to heat and pressure between opposed smooth flat pressing surfaces, and in the course of the pressing of each rod ring evacuating the air from the center of the ring to rarefy the atmosphere in the pressing zone and avoid entrapment of air in the finished sheet ring blank.

17. In combination in apparatus for pressing fiat plastic sheets of ring form from ring shaped plastic material, means comprising a first smooth 10 pressing platen for supporting a plastic ring to be pressed, a tubular structure cooperable with said first platen to sealingly enclose the area occupied by said ring of material to be pressed, 2. piston structure slidably guided wthin said tubular structure and having a second pressing platen opposed to said first platen for pressing the plastic ring therebetween into a fiat ring shaped sheet, at least one of said platens having a central opening therein, and means for substantially evacuating the atmosphere between said platens through said opening contemporaneously with the pressing operation.

GEORGE ALBERT LYON.

REFERENCES CITED The following references are of record in the file of this patent:

UNITED STATES PATENTS Number Name Date 356,879 Lister Feb. 1, 1887 511,751 Britten Jan. 2, 1894 1,657,227 Owen Jan. 24, 1928 1,706,874 De Journo Mar. 26, 1929 1,754,502 Denmire Apr. 15, 1930 1,793,089 Heyes Feb. 17, 1931 2,027,165 Grubman Jan. 7, 1936 2,120,328 Ferngren June 14, 1938 2,159,779 Gavin May 23, 1939 2,272,009 Keller et a1. Feb. 3, 1942 2,350,175 Luxenberger May 30, 1944 FOREIGN PATENTS Number Country Date 508,598 Great Britain July 4, 1939 737,827 France Oct. 10, 1932 

